Method of vacuum packaging a single use disposable diaper

ABSTRACT

Vacuum packed absorbent articles including diapers, kits thereof, and retail packages including vacuum packed and non vacuum packed absorbent articles are disclosed.

I. CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of U.S. patent applicationSer. No. 10/907,389, filed Mar. 31, 2005, now abandoned, which is acontinuation of U.S. patent application Ser. No. 10/907,333, filed Mar.29, 2005, now abandoned, which is a continuation-in-part of U.S. patentapplication Ser. No. 10/665,169, filed Sep. 18, 2003, now abandoned,which claims priority to U.S. provisional patent application Ser. No.60/451,433, filed Mar. 4, 2003. Application Ser. No. 10/907,333 and10/907,389 each claims priority to U.S. provisional patent applicationSer. No. 60/660,792, filed on Mar. 11, 2005.

Each of the disclosures of these patent applications and publishedpatent applications are hereby incorporated herein by reference.Additionally, the present application furthermore hereby incorporates byreference herein U.S. patent application publication no. US 2004/0167489A1.

II. BACKGROUND

The present application relates generally to disposable packaged diapersand related infant and incontinent adult care accessories. Moreparticularly, the present application relates to a reduced size packageddiaper, and related infant and incontinent adult care accessories andkits. The present application also relates to a combination package forretail sale (hereinafter “COMBO PACK”) that includes reduced andnon-reduced articles and, in particular, reduced diapers and non-reduceddiapers.

Diapers are generally a necessity for very young children andincontinent adults. Individuals incapable of controlling the release ofbodily waste in a manner sufficiently reliable to enable the use ofrestroom facilities, and those caring for such individuals, typicallyneed to carry extra disposable diapers and changing accessories. This istypically because it is difficult to predict when a diaper worn by anindividual may need to be changed. Caretakers of babies and othersrequiring diapers often carry spare, clean diapers for this reason.

Many of the following discussions and examples are directed to use ofdiapers in infant care. However, it will be apparent that many of thesame considerations apply to use of diapers for non-infant, incontinentpersons.

Storage and carriage of clean diapers is often inconvenient. Forinstance, disposable diapers are generally rather bulky items not givento easy storage or carriage in a purse, pocket, or otherwise about theperson. In addition, the problem can be acerbated in that diapers can besubject to expansion from the typically somewhat compressed state inwhich they are normally provided to consumers, especially incircumstances where the diapers are subject to contact with other itemswithin a storage bag. For example, many disposable diapers are providedin a bi-fold configuration meant to minimize the space taken in storingthe diaper. However, after being removed from their original packaging,bi-fold diapers often unfold or otherwise expand to consume an evenlarger storage space. Thus, disposable diapers can become more bulky anddifficult to carry than when in their nominal, packaged condition.

In addition, it is often the case that it is not sufficient to simplychange a soiled diaper and replace it with a clean diaper. For instance,cleaning of the individual who wore the diaper may need to be performedwith diaper accessories, such as moist wipes. Also, it may be necessaryto apply ointment or powder to the individual wearing the diaper totreat or prevent incidents of diaper rash or other skin conditions. Dueto these considerations, caretakers of individuals requiring diapersoften carry clean diapers and diaper changing accessories in a dedicatedcontainer, is often referred to as a “diaper bag.” By doing so, when itbecomes necessary to change a diaper, all of the materials needed by thecaretaker are available in one location.

While a conventional diaper bag provides a dedicated container in whichdiapers and diaper accessories can be stored and carried, therequirement of carriage of a diaper bag often adds to the difficulty ofa caretaker's responsibility. For example, parents of young childrenoften must carry a purse or briefcase for the parent's own needs. Inaddition to this, the parent may need to carry the young child; and, ofcourse, the child's diaper bag. This can leave the parent with no freehands for other tasks.

While conventional clean diapers and diaper changing accessories can bestored and carried in other carrying containers such as purses,backpacks, briefcases, etc., the bulky nature of conventional disposablediapers results in the diapers occupying a relatively large space withinthe carrying container. In addition, diaper changing accessories such asmoist wipes, ointment, powder, etc., add to the space consumed byconventional clean diapers and can be difficult to locate among otheritems stored in the backpack, purse, case, or the like.

Where the diapers being carried by the caretaker are for bottle feedinginfants, the problems discussed above are further exacerbated by theneed to carry materials for feeding the baby. In addition to theaccoutrement necessary to attending to changing the baby's diaper,things such as bottles, nipples, containers of formula or milk, etc.,generally must also be carried.

III. SUMMARY OF THE INVENTION OF THE PRESENT APPLICATION

It has been recognized that it would be advantageous to develop apackaged diaper that requires a relatively small amount of storagespace. In addition, it has been recognized that it would be advantageousto develop a diaper and related accessory kit that consumes a relativelysmall amount of space while providing substantially all of the materialsnecessary to change an individual's diaper. It has also been recognizedthat it would be advantageous to develop an infant care kit thatconsumes a relatively small amount of space while providingsubstantially all of the materials necessary to feed the infant andchange the infant's diaper.

The invention of the present application provides a packaged diaper,including a diaper, having a first, nominal size, and a second, reducedsize, the reduced size of the diaper being convenient for carriage andstorage of the diaper. An encasement can also be provided, in which thediaper can be disposed in the second, reduced size. The encasement canconfine the diaper so that the diaper is retained in its reduced size bythe encasement and so that the diaper is returned to its nominal sizeupon opening of the encasement.

In accordance with another aspect of the invention of the presentapplication, a packaged diaper is provided, including a diaper, having afirst, nominal configuration characterized by a nominal length, widthand height, and a second, reduced configuration characterized by asecond, reduced length, width and height. The reduced length can bebetween about 2 inches to about 4 inches, the reduced width can bebetween about 1.0 inch to about 2.5 inches, and the reduced thicknesscan be between about 0.5 inches to about 1.5 inches. An encasement canalso be provided, in which the diaper can be disposed and retained inthe second, reduced configuration.

In accordance with another aspect of the invention of the presentapplication, a packaged diaper is provided, including a diaper, having afirst, nominal size and shape, and a reduced, substantially cylindricalsize and shape. The reduced, substantially cylindrical shape can have adiameter between about 0.5 inches to about 1.5 inches and a lengthbetween about 2 inches to about 4 inches. An encasement can also beprovided, in which the diaper can be disposed and retained in thereduced, substantially cylindrical shape.

In accordance with another aspect of the invention of the presentapplication, a packaged diaper is provided, including a diaper having afirst, nominal volumetric configuration characterized by a nominallength and width of the diaper, and a second, reduced volumetricconfiguration characterized by a reduced length and width of the diaper.An encasement can also be provided, the encasement formed of asubstantially air impermeable material. The diaper can be disposed inthe encasement in the second, reduced volumetric configuration and theencasement can be at least partially evacuated of air so as to containthe diaper in at least a partial vacuum state. Differential pressurewithin and without the encasement can maintain the second, reducedvolumetric configuration of the diaper and the encasement can be sealedto confine the diaper so that the diaper is returned to its nominalvolumetric configuration upon opening of the encasement.

In accordance with another aspect of the invention of the presentapplication, a method of packaging a diaper is provided and includes thesteps of: a) folding the diaper at least once along both a lengthwiseand a crosswise aspect of the diaper; b) disposing the folded diaperwithin an encasement comprised of a substantially air impermeablematerial; c) evacuating air from the encasement and the folded diaper;and d) sealing the encasement to maintain a vacuum created within theencasement and the folded diaper.

In accordance with another aspect of the invention of the presentapplication, a method of packaging a diaper is provided and includes thesteps of: a) volumetrically reducing a size of the diaper to a sizeconvenient for carriage and storage of the diaper; b) disposing thevolumetrically reduced diaper within an encasement; and c) maintainingthe volumetrically reduced size of the diaper with the encasement.

In a more detailed aspect, the encasement can facilitate this by virtueof its hoop strength and/or by means of a pressure differential actingupon the encasement.

In accordance with another aspect of the invention of the presentapplication, a diaper changing kit is provided and includes a packageddiaper in accordance with one or more previously set forth aspects ofthe invention of the present application, at least one diaper accessory,and a container in which the packaged diaper and the diaper accessorycan be disposed. In a more detailed aspect, the accessory can be one ormore of: a) a moistened wipe; b) baby powder; c) a medicament; d) aswab; e) a lotion; and, a disposal bag for a dirty diaper. In anothermore detailed aspect the container can be configured to have a first,oversized size and shape and a second smaller size and shape, and toalso function as a disposal container for a dirty diaper.

In accordance with another aspect of the invention of the presentapplication, an infant care kit is provided and includes a diaper, adiaper accessory, a portion of infant food and an infant feedingassembly. The infant feeding assembly can have a hollow body and anipple portion couplable thereto. The diaper, diaper accessory, andportion of infant food can each be disposed in the infant feedingassembly. The infant feeding assembly can be configured to: i) containeach of the diaper, at least one diaper accessory and at least oneportion of infant food; and ii) upon removal of the diaper and diaperaccessory, receive the portion of infant food within the hollow body anddeliver the infant food to an infant with the food delivery device. In amore detailed aspect a warming pack can also be provided for warming theinfant food.

In accordance with another aspect of the invention of the presentapplication, a packaged diaper is provided and includes a diaper, havinga first, nominal size, and a second, reduced size, the reduced size ofthe diaper being convenient for carriage and storage of the diaper. Arestraint can also be provided, in which the diaper can be disposed inthe second, reduced size. The restraint can confine the diaper so thatthe diaper is retained in its reduced size by the restraint and so thatthe diaper is returned to its nominal size upon opening of therestraint.

In accordance with another aspect of the invention of the presentapplication, a packaged diaper is provided and includes a densifieddiaper volumetrically reduced to a second reduced volume and increaseddensity from a first greater volume and lesser nominal density. Thereduction of the diaper can entail reduction in one or more dimensions.An encasement can also be provided in which the diaper can be disposedin the second reduced volume. The encasement can confine the diaper sothat the diaper is retained in the reduced volume by the encasement.

In accordance with another aspect of the invention of the presentapplication, an expandable diaper is provided and includes a diaperbeing reduced to a second, reduced size from a first, nominal size, thereduced size of the diaper being reduced in at least two dimensionaldirections relative to the nominal size. An encasement can also beprovided in which the diaper can be disposed in the second, reducedsize. The encasement can confine the diaper so that the diaper isretained in the reduced size by virtue of the encasement.

In accordance with another aspect of the invention of the presentapplication, a packaged diaper is provided and includes a diaper, havinga first, nominal size, and a second, reduced size, the reduced size ofthe diaper being convenient for carriage and storage of the diaper. Arestraint can also be provided in which the diaper can be disposed inthe second, reduced size. The restraint can confine the diaper so thatthe diaper is retained in its reduced size by the restraint and so thatthe diaper is returned to its nominal size upon opening of therestraint.

In addition to the foregoing, one or more other aspects of the inventionrelates to a method for miniaturizing a diaper. In this respect, apreferred such method comprises: folding a diaper within a jig;transferring the folded compressed diaper from the jig using a clampingapparatus; inserting the folded compressed diaper into a pliable bag;and vacuum sealing the bag thereby further miniaturizing the diaperwithin the bag. The miniaturized finished product preferably fits into aconveniently sized box for eliminating the bulky nature of carryingbulky diapers within a purse or other carrying case. Furthermore, thefinished product is condensed down to a firm and hard exterior surface,and may be disguised in appearance, for example, to look like a candybar instead of a baby diaper or an adult diaper. The miniaturizationprocess can be readily adapted to mechanical application for automaticmanufacturing assembly line runs.

Still yet, other inventive aspects and features of the invention are setforth in U.S. patent application Ser. No. 11/927,232, and itscorresponding publication U.S. patent application publication no.2008/0128295, both of which are incorporated herein by reference.

Additional aspects and features, and advantages thereof, will beapparent from the detailed description which follows, taken inconjunction with the accompanying drawings, which together illustrate,by way of example, features of the invention of the present application.In addition to the aforementioned aspects and features of the presentinvention, it should be noted that the present invention furtherencompasses the various possible combinations of such aspects andfeatures.

IV. BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a top view of a diaper in a nominal configuration;

FIG. 1B is a side view of the diaper of FIG. 1A;

FIG. 2A is a top view of a diaper in a volumetrically reducedconfiguration;

FIG. 2B is a side view of the diaper of FIG. 2A;

FIG. 3A is a perspective view of a diaper;

FIG. 3B is a perspective view of the diaper of FIG. 3A in the process offolding the diaper along a lengthwise aspect of the diaper;

FIG. 3C is a perspective view of the diaper of FIG. 3B in the process offolding the diaper along a crosswise aspect of the diaper;

FIG. 3D is a perspective view of the diaper of FIG. 3C being disposedwithin an encasement;

FIG. 3E is a perspective view of the diaper of FIG. 3D held under vacuumwithin the encasement of FIG. 3D;

FIG. 4 is an end view of a packaged diaper having a reduced volume in asubstantially cylindrical shape;

FIG. 5 is a perspective view of a diaper kit;

FIG. 6 is a perspective view of another diaper kit;

FIG. 6A is a perspective view of a diaper wipe configuration usable withthe kit of FIG. 6 in one example;

FIG. 7 is a perspective view of an infant care kit;

FIG. 8 is a perspective view of a master container;

FIG. 9A is a top view of another diaper kit;

FIG. 9B is a side view of the diaper kit of FIG. 9A;

FIG. 9C is a side view of another example diaper kit;

FIG. 10A is a schematic view of one step of a process of packaging adiaper;

FIG. 10B is a schematic view of another step of the process of FIG. 10A;

FIG. 10C is a schematic view of another step of the process of FIG. 10A;

FIG. 10D is a schematic view of another step of the process of FIG. 10A;

FIG. 10E is a schematic view of another step of the process of FIG. 10A;

FIG. 11A is a perspective view of a diaper held by a restraint;

FIG. 11B is a perspective view of a diaper held by another restraint;

FIG. 12 is a view of a bulky diaper in the hands of a person;

FIG. 13 is a sketch of a diaper within a jig made for holding andfolding said diaper, with a person tucking the rough edges inwardly;

FIG. 14 is a view of a diaper with one end being folded inward;

FIG. 15 is a view of a diaper with the other end being folded inwardover the first fold;

FIG. 16 shows a hand clamp gripping a folded diaper;

FIG. 17 is a perspective view of a folding jig facilitating the handclamp for inserting a diaper into a plastic bag;

FIG. 18 shows a hand clamp held by a person compressing a folded diaperbeing inserted into a plastic bag;

FIG. 19 shows a folded and compressed diaper within a small plastic bag;

FIG. 20 shows a folded, compressed, and vacuum-packed diaper within theplastic bag of FIG. 19 after vacuum-sealing;

FIG. 21A is a schematic view of one step of a method of packaging adiaper;

FIG. 21B is a schematic view of another step of the method of FIG. 21A;

FIG. 21C is a schematic view of another step of the method of FIG. 21A;

FIG. 21D is a schematic view of another step of the method of FIG. 21A;

FIG. 21E is a schematic view of another step of the method of FIG. 21A;

FIG. 22 is an illustration of a method for pressing a vacuum-packeddiaper;

FIG. 23 is an illustration of another method for pressing avacuum-packed diaper;

FIG. 24 is an illustration of another method for pressing avacuum-packed diaper;

FIG. 25 is an illustration of another method for pressing avacuum-packed diaper;

FIG. 26 is an illustration of another method for pressing avacuum-packed diaper;

FIG. 27 is a view of a fully extended diaper having indicia thereon;

FIG. 28 is a view of the diaper of FIG. 27 with tucked end margins;

FIG. 29A and FIG. 29B are views of the diaper of FIG. 28 with tuckedside margins;

FIG. 30 is a view of the diaper of FIGS. 29A and 29B with a crosswisefold;

FIG. 31A and FIG. 31B are views of the diaper of FIG. 30 aftervacuum-packing;

FIG. 32 is a view of another fully extended diaper having indiciathereon;

FIG. 33A and FIG. 33B are views of the diaper of FIG. 32 aftertucking/folding and vacuum-packing;

FIG. 34 is a view of another fully extended diaper having indiciathereon;

FIG. 35A and FIG. 35B are views of the diaper of FIG. 34 aftertucking/folding and vacuum-packing;

FIG. 36A, FIG. 36B, and FIG. 37 are views of a kit having avacuum-packed diaper and diaper accessories, wherein indicia of thediaper is visible through the encasement in which the diaper isvacuum-sealed.

FIGS. 38-39 illustrate a disguisedly packaged absorbent article whereinthe package resembles a candy bar;

FIG. 40 illustrates the configuration of the absorbent article disposedwithin the package of FIGS. 74-75;

FIG. 41 illustrates another disguisedly packaged absorbent articlewherein the package resembles a candy bar;

FIG. 42 illustrates the configuration of the absorbent article disposedwithin the package of FIG. 41;

FIG. 43 illustrates another disguisedly packaged absorbent articlewherein the package resembles a pack of cigarettes;

FIG. 44 illustrates the absorbent article and accessories containedwithin the package of FIG. 43;

FIGS. 45-46 illustrate another disguisedly packaged absorbent articlewherein the package resembles a mobile phone;

FIG. 47 illustrates separation of the encasement of FIGS. 45-46resembling the mobile phone for accessing of the absorbent articlecontained therein;

FIG. 48 illustrates the attachment of the clamping band to the shells ofthe encasement of FIGS. 45-46 resembling the mobile phone;

FIG. 49 further illustrates the package of FIGS. 45-46 followingattachment of the clamping band as shown in FIG. 48;

FIGS. 50-51 illustrate another disguisedly packaged absorbent articlewherein the package resembles a pager;

FIG. 52 illustrates separation of the pager of FIGS. 50-51 for accessingof the absorbent article contained therein;

FIG. 53 is an illustration of a toy container;

FIG. 54 is an exploded view of the toy container of FIG. 53;

FIG. 55 is an illustration of another toy container;

FIG. 56 is an exploded view of the toy container of FIG. 55;

FIGS. 57-59 are illustrations of a toy container;

FIG. 60 is an illustration of a volumetrically reduced diaper that isdisposed within the toy container of FIGS. 57-59;

FIGS. 61-62 are illustrations of another toy container;

FIG. 63 is an illustration of a volumetrically reduced diaper that isdisposed within the toy container of FIGS. 61-62;

FIGS. 64-66 are illustrations of still yet another toy container;

FIGS. 67-68 are illustrations of a volumetrically reduced diaper that isdisposed within the toy container of FIGS. 64-6;

FIG. 69 is an illustration of a method of making the volumetricallyreduced diaper of FIGS. 67-68;

FIG. 70 is an illustration of a vending machine;

FIG. 71 is cross-sectional illustration of the vending machine of FIG.70 taken along the line 71-71 in FIG. 70;

FIG. 72 is an illustration of a COMBO PACK having a first package and asecond package;

FIG. 73 shows a vacuum-packed diaper within the second package of FIG.72;

FIG. 74 shows the vacuum-packed diaper removed from the second packageof FIG. 73;

FIG. 75 is an illustration of a COMBO PACK having a first package and atransparent encasement that contains a vacuum-packed diaper;

FIG. 76 is an illustration image of a COMBO PACK that includes avacuum-packed diaper and a number of non vacuum-packed diapers allcontained within a first package;

FIG. 77 is another view of the COMBO PACK of FIG. 76;

FIG. 78 illustrates a vacuum-packed diaper and a non vacuum-packeddiaper of FIG. 76 after having been removed from the first package.

FIG. 79 is an illustration of a COMBO PACK having a first package thatincludes a number of non vacuum-packed diapers and two diapers that havebeen vacuum-packed together and that are contained within the sametransparent encasement;

FIG. 80 illustrates three examples of vacuum-packed diapers that may becombined with non-vacuum packed diapers of the first packaged, includinga “C” folded vacuum-packed diaper, a “twin” pack of “C” foldedvacuum-packed diapers, and a flat vacuum-packed diaper;

FIG. 81 is an illustration of a COMBO PACK that includes a vacuum-packeddiaper within a second package, wherein the second package is disposedwithin a first package that itself contains a number of nonvacuum-packed diapers;

FIG. 82 is an illustration of a COMBO PACK that includes a first packageof non vacuum-packed diapers and a vacuum-packed diaper removablyattached to the first package;

FIG. 83 is another view of the COMBO PACK of FIG. 82 illustrating, inpart, the elephant cartoon character that is prominently printed on thediaper through the transparent encasement containing the vacuum-packeddiaper;

FIG. 84 is an illustration of a COMBO PACK that includes a vacuum-packeddiaper and a number of non vacuum-packed diapers;

FIG. 85 is an illustration of an embodiment of a COMBO PACK thatincludes within a first package not only the non vacuum-packed diapers,but also a “6-Pack” dispenser which, itself, contains six kits eachhaving, inter alia, an individually vacuum-packed diaper;

FIG. 86 is a photographic image of the “6-Pack” dispenser removed fromthe first package of FIG. 85;

FIG. 87 is a photographic image of a kit (in this embodiment, thecontainer of the kit comprises a box) that is partially removed from thedispenser of FIG. 86;

FIG. 88 is an illustration of three boxes, each of which is used as acontainer for a kit, with each kit including therein at least avacuum-packed diaper and wherein each box is removable from the 6-Packdispenser of FIG. 86, which dispenser also is illustrated in FIG. 88;

FIG. 89 is an illustration of still yet another embodiment of a COMBOPACK that includes of a first package containing the non vacuum-packeddiapers and a kit containing, inter alia, a vacuum-packed diaper;

FIG. 90 is an illustration of the kit of FIG. 89 removed from the firstpackage;

FIG. 91 is another view of the kit of FIG. 89 removed from the firstpackage, which view illustrates a panel of the box which hinges;

FIG. 92 is still yet another illustration of the kit of FIG. 89 removedfrom the first packaged, the image comprising a close-up of the side ofthe kit shown in FIG. 90 to illustrate a resealable label that permitsaccess to one or more contents of the kit;

FIG. 93 is an illustration of two additional kits that may be used;

FIG. 94 is an illustration of the other side of one of the kits (thelarger box) of FIG. 93;

FIG. 95 is an illustration of the other side of the other kit (thesmaller box) of FIG. 93;

FIG. 96 is an illustration of still yet another kit that may be used,wherein the container of this illustrated kit comprises a bag made fromone or more flexible sheets or films;

FIG. 97 is another view of the kit of FIG. 96;

FIG. 98 is another view of the kit of FIG. 96;

FIG. 99 is another view of the kit of FIG. 96;

FIG. 100 is another view of the kit of FIG. 96 together with a rulerillustrating the length of the kit to be approximately five (5) inches;

FIG. 101 is another view of the kit of FIG. 96 together with a ruleillustrating the thickness of the kit to be approximately two (2)inches;

FIG. 102 is an illustration of a preferred arrangement of two 6-Packdispensers and non-vacuum-packed diapers sandwiched therebetween fordisposition in a package to form a COMBO PACK;

FIG. 103 is an illustration of various package form factors that cancontain a vacuum-packed diaper for inclusion in a package of diapers;

FIG. 104 is a view of a bulky diaper in the hands of a person;

FIG. 105 is a sketch of a diaper within a jig made for holding andfolding said diaper, with a person folding the rough edges inwardly;

FIG. 106 is a view of a diaper with one end being folded inward;

FIG. 107 is a view of a diaper with the other end being folded inwardover the first fold;

FIG. 108 shows a hand clamp gripping a folded diaper;

FIG. 109 shows a hand clamp held by a person compressing a folded diaperbeing inserted into a plastic bag;

FIG. 110 is a perspective view of a folding jig facilitating the handclamp for inserting a diaper into a plastic bag;

FIG. 111 a folded and compressed diaper within a small plastic bag;

FIG. 112 a folded and compressed diaper within a small plastic bag beingpositioned within a vacuum sealing machine;

FIG. 113 shows a vacuum sealed diaper within a plastic bag held by aperson;

FIG. 114 is an illustration of a bulky diaper in the hands of a person;

FIG. 115 is an illustration of the diaper in a jig made for holding andfolding said diaper, with a person folding the rough edges inwardly;

FIG. 116 is an illustration of a first end of the diaper in the jigfolded inwardly covering a middle portion of the diaper;

FIG. 117 is an illustration of the other end of the diaper folded inover the first end and middle portion thereby forming a rectangularshape;

FIG. 118 is an illustration of a spring tensioned hand clamp opened withone hand so as to have the upper flat rectangular jaw and lower jawplaced over and under the completely folded diaper;

FIG. 119 is an illustration of the spring tensioned hand clamp anddiaper retained therein;

FIG. 120 is an illustration of the spring tensioned hand clamp anddiaper retained therein;

FIG. 121 is an illustration of the folded diaper having been compressedbeing inserted into an open end of an elastic pliable resilient bagusing the hand clamp and jig to facilitate insertion;

FIG. 122 is an illustration of the folded diaper having been compressedbeing inserted into an open end of an elastic pliable resilient bagusing the hand clamp and jig to facilitate insertion;

FIG. 123 is an illustration of the folded diaper, compressed by the handclamp, being directly inserted into the open ended bag by hand;

FIG. 124 is an illustration of the folded diaper, compressed by the handclamp, being directly inserted into the open ended bag by hand

FIG. 125 is an illustration of the folded diaper fully inserted into thebag;

FIG. 126 is an illustration of the folded diaper fully inserted into thebag being placed into a vacuum sealing machine on a deck thereof;

FIG. 127 is an illustration of the folded diaper fully inserted into thebag being placed into a vacuum sealing machine on a deck thereof;

FIG. 128 is an illustration of the folded diaper fully inserted into thebag being placed into a vacuum sealing machine on a deck thereof;

FIG. 129 is an illustration of a “Vac-U-Diaper” product after the vacuumsealing machine vacuum seals and cuts the bag.

V. DETAILED DESCRIPTION

Reference will now be made to the exemplary embodiments illustrated inthe drawings, and specific language will be used herein to describe thesame. It will nevertheless be understood that no limitation of the scopeof the invention is thereby intended. Alterations and furthermodifications of the inventive features illustrated herein, andadditional applications of the principles of the inventions asillustrated therein, which would occur to one skilled in the relevantart and having possession of this disclosure, are to be consideredwithin the scope of the invention.

As illustrated in FIGS. 1A through 2B, an exemplary packaged,disposable, diaper 10 is sized and shaped to consume a considerablysmaller volume and be more conveniently shaped than conventionaldisposable diapers. As illustrated, the packaged diaper 10 begins as adiaper 12 nominally sized and shaped in accordance with conventionaldiapers. The diaper can be one of a variety of types known to those inthe art, and can be formed of a variety of materials. The diaper can bedisposable or non-disposable (i.e., resusable).

As shown in FIG. 1A, the diaper begins with a first, nominal volumetricconfiguration characterized by a nominal length L and nominal width W ofthe diaper. As used herein, the term “nominal” is understood to mean tobe the normal, post manufacturing state in which it is ready to beunfolded and worn, in reference to the various dimensions of the diaper.Thus, the diaper 12 can have a first size having a height, width andlength of nominal size, such as conventionally provided to consumers.While not so required, the diaper 12 can include upper 12 a and lower 12b portions, which can correspond to a front and back of the diaper. Manyconventional diapers are provided with a front and back portion ofdifferent configuration.

As shown in FIGS. 2A and 2B, an example of a packaged diaper 10, afterbeing prepared in accordance with the description to follow below,includes a diaper 12 having a second, reduced volumetric configurationcharacterized by a reduced length L₂ and width W₂ of the diaper 12. Thereduced volumetric configuration can differ from the nominal volumetricconfiguration in width, height, thickness, volume and overall size. Aswill be appreciated from the figures, not only is the volume of thepackaged diaper reduced overall, but in the example embodiment at leasttwo of the length, width and height can also be reduced. Thus, thediaper can be reduced in volumetric configuration to consume much lessspace than the diaper consumes when in the nominal configuration.

As mentioned, the diaper 12 can be disposed in an encasement 14, whichcan be formed of a substantially air impermeable material. By disposingthe diaper in the encasement in the second, reduced volumetricconfiguration, a packaged diaper is provided that consumes much lessspace than the when in its nominal configuration. By “substantially airimpermeable,” what is meant is that the permeability is low enough thatthe product has a reasonable shelf life without significant expansion.

As an example, it has been found that by drawing a vacuum down to about5 Mbar at room temperature and pressure at a location about 5,000 feetelevation above mean sea level, the volume of the diaper can be reducedto as little as ⅓ or ¼ that of the nominal volume. Similar results areto be expected at locations of different elevation. However, as isknown, at lower elevations a greater vacuum can be drawn to allow forsubsequent transportation of the packaged product to higher elevations.For example, vacuum packaging using a vacuum down to 1 or 2 Mbar iscommon at lower elevations. Thus, in the space required to store oneconventional diaper, three, four, or more, diapers packaged can bestored. The reduced volume packaged diapers are not only advantageous inreducing storage space, the space required for packaging, shipping,etc., is also reduced, leading to considerable cost savings inassociated processes.

While the reduced volume configuration can be created and maintained ina number of ways, in the embodiment shown in FIGS. 2A and 2B, thepackaged diaper 10 includes encasement 14, which can encompass thereduced volume diaper. Once the diaper 12 is disposed within theencasement, the encasement can be at least partially evacuated of air soas to contain the diaper in at least a partial vacuum state. Theevacuation of air from within the diaper and encasement can be done in anumber of ways, such as by conventional vacuum-packing methods.

For example, according to at least one conventional vacuum-packingmethod known to those skilled in the relevant art, an article to bevacuum-packed is inserted into an unsealed encasement formed of asubstantially air impermeable flexible material. The unsealed encasementwith the article therein is then placed onto the deck of avacuum-sealing machine. The lid of the machine is then loweredestablishing a seal with the deck and to define a chamber between thedeck and the lid with the unsealed encased article within the chamber. Apumping system then evacuates ambient air from the chamber creating atleast a partial vacuum state within the chamber and within the interiorspace of the unsealed encasement with the article therein. Sealing barsthen seal the encasement to maintain at least a partial vacuum statetherein. Ambient air pressure is then restored to the chamber effectinga pressure differential across the sealed encasement. Insofar as thearticle within the sealed flexible encasement is compressible, thepressure differential acts upon the encasement to compress the articleand maintains the article in a reduced volume that is less than thevolume of the article at the time the encasement was sealed (beforeambient air pressure was restored to the chamber). The lid of themachine is then raised and the vacuum-packed article is available forremoval from the machine.

Upon evacuation of air from the encasement, the encasement can besealed, for example at an edge portion 16 to maintain the vacuum withinthe encasement and diaper 12. In this manner a differential pressure canbe created within and without the encasement to maintain the second,reduced volumetric configuration of the diaper. While the encasement isshown in FIG. 2B as sealed at an edge portion 16, it will be understoodthat the encasement can be sealed conventionally in a variety of ways ina variety of locations.

As the encasement 14 configured to confine the diaper 12 is unsealed,the diaper is able to return to its nominal volumetric configuration.That is, user can cut, tear, remove a portion of the encasement, orotherwise break the airtight seal of the encasement; after which, thediaper 12 will no longer be subject to confining force due to theencasement and/or a pressure differential. Unopposed rebound forces inthe materials from which the diaper is made will tend to return it toits nominal configuration. The encasement can include a means tofacilitate opening, such as a notch or another intentionally formeddiscontinuity (not shown) provided in the encasement to aid in openingthe encasement. In one embodiment a tear-away band, or the like,provided with a grasping tab (not shown) can be provided to facilitateopening by rupturing the encasement as it is pulled away therefrom. Oneof many other well known ways to provide a more easily broken-openencasement can be used to facilitate opening the packaging.

As described in further detail below, the reduced volumetricconfiguration can be achieved in a number of ways, and in the embodimentshown in FIGS. 2A and 2B, the volumetrically reduced configuration iscreated by foldingly reducing a length and width of the diaper 12;increasing its thickness. The folded diaper is then vacuum-packed toreduce its thickness (as well as its width and length to a lesserextent). As used herein, the term “foldedly reduced” is meant toindicate the case wherein a diaper is folded or rolled over or underitself to thereby reduce a dimension of the diaper. While the final sizeof the reduced volume diaper can vary, in one embodiment the reducedlength and width can each be less than about ½ of the nominal length andwidth, respectively, of the diaper. In another embodiment, the foldedlyreduced length of the diaper can be less than about ⅓ and/or ¼ of thenominal length of the diaper. In this manner, as shown by comparingFIGS. 1A and 1B with FIGS. 2A and 2B, the overall width and length ofthe diaper can be substantially reduced. While a height dimension,corresponding to thickness, may be increased, it is not increased toexceed the width or the length of the diaper. This results in a moreconvenient and compact size overall.

The inventor has found that a conventional size 6 diaper can be reducedin size and volume from a nominal size of approximately 9″ long by 4.5″wide by ¼″ to 1″ in height/thickness (depending on expansion afterremoval from conventional packaging) to a reduced size of approximately3.5″ long by 2.25″ wide by 1″ in height. In the embodiment shown inFIGS. 2A and 2B, the packaged diaper 10 can include a reduced volumetricshape configuration which comprises a substantially rectangular shape,although other shapes are contemplated as well, as discussed in furtherdetail below. In this manner, the packaged diaper can be easily carried,handled and stored within a purse, pocket, bag or other place orcontainment for carriage.

The packaged diaper in a densified state can thus be made pocket sized,or pocketable. As used herein that means that it is conveniently sizedfor carriage, for example about the size of a conventional cigarettepackage or smaller. One way to characterize this is that two of thethree dimensions of height width and length, when added together, areless than 10 cm, and the greatest of the three does not exceed 10centimeters. That said, all pocket sized items may not strictly fit thisdefinition, but it is a definite guide in understanding what is meant bythe term as used herein.

It will be appreciated that in this example a compact, efficiently sizedpackaged diaper is provided that requires substantially less space thanconventionally packaged diapers. The packaged diaper can beadvantageously utilized by a variety of persons, including incontinentminors and adults, and caretakers of individuals requiring diapers.

For example, parents of young children will benefit in that one or morediapers 10 can be easily stored in a pocket, or within a purse,briefcase, backpack or other storage bag and consume relatively littlespace. Similar benefits can be obtained with regard to incontinentadults, as adult diapers are generally even more bulky and difficult tostore and carry than are smaller, children's diapers. Also, incontinentadults who may be otherwise embarrassed by having to carry spare cleandiapers will likely find the packaged diapers to be much more discreetlytransportable, and therefore the carriage of such spare diapers muchless noticeable by others.

Additionally, in one aspect pocketable diaper is provided and caninclude an encasement configured to encase and confine a diaper disposedtherein. A diaper can be disposed within the encasement to be confinedby the encasement in a size that is volumetrically reduced relative to anominal size of the diaper. The volumetrically reduced size of thediaper is characterized in that the diaper is pocketable upon a personof an individual. As used herein, the term “pocketable” is to beunderstood to indicate a configuration of the diaper in which the diapercan be easily placed within and removed from a pocket of an item ofclothing or accessories worn or carried by individuals. For example, thepocketable diaper can be held within a shirt, jacket or pants pocket orstored or carried in a handbag, purse or briefcase, etc., and can besubstantially undetectable by other individuals. In this manner, anincontinent adult can carry the pocketable diaper without worrying thatothers will be aware that the diaper is being carried. Also, an adultcaretaker of an infant can carry a diaper for the infant in a mannerthat does not detract from a physical appearance of the adult and doesnot require additional baggage.

In several embodiments, a reduced diaper is provided. The reduced diaperis densified by volumetric reduction from a first greater volume andlesser nominal density to a second reduced volume and increased density.An encasement can also be included and the diaper can be disposed in theencasement in the second reduced volume. The encasement can therebyconfine the reduced diaper so that the diaper is retained in the reducedvolume by the encasement. The volumetric reduction can entaildimensional reductions in width, thickness, length, and diameter. Inthis manner, a volumetrically reduced, space-efficient densified diaperis provided that can be easily stored and carried by an individual in adiscreet manner. Upon release of the reduced diaper from the encasement,the diaper can be volumetrically expanded and used in the same manner asconventionally packaged diapers.

As used herein, the term “encasement” is to be understood to encompass abroad range of materials and configurations for containing orrestraining or enclosing a volumetrically reduced diaper. For example,the encasement may completely encompass a diaper and hold the diaperunder a vacuum seal or other pressure differential. In addition, theencasement may only partially encompass the diaper to maintain thecompressed state of the diaper. Moreover, it is intended to beunderstood herein to be synonymous with restraint (as discussed below)or enclosure, or containment, in this context. The salient point beingthat it constrains, by some means, the densified diaper from expanding.Other encasements besides the examples shown can also be utilized, aswould occur to one skilled in the art.

Shown in series in FIGS. 3A through 3E is an aspect in which a diaper isreduced from its nominal volume or size to a reduced volume or size.Diaper 12 begins with a nominal volumetric configuration, sized andshaped as may be conventionally provided by a manufacturer of thediaper. In this embodiment, the diaper is reduced in volume by fold 17along a lengthwise aspect of the diaper, shown at line 18. In FIG. 3C,the diaper 12 is folded at 19 along a crosswise aspect of the diaper,shown at line 20. Progressing to FIG. 3D, once the diaper has beenfolded a desired number of times; the folded diaper is disposed withinencasement 14, which is formed of a substantially air impermeablematerial. Encasement 14 can then be evacuated to form a relative vacuumwithin the encasement, after which the encasement can be sealed tomaintain the vacuum in the diaper and the encasement.

It will be understood by those skilled in the art that the process offorming a vacuum within the diaper and the encasement will extract atleast a portion of air contained within the diaper. By removing amajority of excess air from the diaper, the diaper can be compressedupon itself by atmospheric pressure and consume a reduced amount ofspace corresponding to the amount and volume of air removed from thediaper.

In addition to the process illustrated in FIGS. 3A through 3E, inanother aspect, a method of packaging a diaper is provided and includesthe steps of volumetrically reducing a size of the diaper to a sizeconvenient for carriage and storage of the diaper. The volumetricallyreduced diaper can then be disposed within an encasement. Thevolumetrically reduced, convenient size of the diaper can be maintainedby a pressure differential acting upon the encasement. As used herein,the term “convenient size” is understood to refer to a size andconfiguration of a diaper that can be easily and conveniently stored ina pocket, handbag, purse, etc., and consume very little space within thepocket, handbag, etc. Such a size will be appreciated to be essentiallya “pelletized” or “capsulated” or “pocket sized” or “pocketable” (asdefined above) version of the diaper, having bulk due to air spacesremoved, and will be generally cylindrical, rectangular, etc, and canhave rounded or square corners. Generally, the largest dimension will beabout four inches or less. However, for certain specialized applicationssuch as kits contained in a feeding bottle, a longer, more “sticklike”shape may be used in one embodiment. But likewise a cylindrical orsquare configuration having height, width, and length dimensions ofroughly equal magnitude can also be advantageous in such a kit inanother embodiment. The salient point is that the size is convenient tocarry and conceal.

The size of the diaper can be volumetrically reduced in a number ofmanners, including pressing the diaper into a mold or other cavity. Inthis example, the encasement in which the diaper is disposed can besized and shaped to correspond closely to the volumetrically reducedsize of the diaper. Once disposed within the encasement, the forceapplied to compress the diaper into the mold can be released, afterwhich the diaper will tend to return to its nominal size and shape, butwill be restrained by the encasement. The pressure differential actingupon the easement will thus be the result of the diaper tending toexpand into its nominal configuration. An equilibrium will be reachedbetween a) the restoring force tending to expand the diaper; and b) acombination of the hoop strength (resistance to expansion of theencasement via deformation of the encasement) and the pressuredifferential tending to compress the diaper. Depending on the materialfrom which the encasement is made, this can be made to be predominantlyhoop strength or predominantly air pressure differential.

While the example packaged diaper shown in many of the figures of thisdisclosure includes a generally rectangular shape, it is contemplatedthat the volumetrically reduced diaper can be of a variety of sizes andshapes. For instance, as shown in FIG. 4, volumetrically reduced diaper12 a can have a substantially cylindrical shape. This embodiment may bebeneficial, for example, in applications in which the diaper is to bestored in rounded or cylindrical receptacles, such as cans or tubes. Aswill be appreciated, by forming encasement 14 a from a flexible,substantially air impermeable material, a vacuum formed within theencasement will force the encasement to conform to the general shape ofthe reduced volume diaper. In this manner, the diaper can be formed in avariety of reduced volume shapes for a variety of applications.

In another example embodiment the encasement shape can control the shapeof the packaged diaper. For example, a diaper can be compressed into anencasement within a mold cavity which encasement has a shape whichessentially follows the shape of the mold. Thereafter the encasementmaintains that shape, though the diaper may expand slightly against thehoop strength, air pressure differential, or combination thereof.

As illustrated in FIG. 5, in another aspect a diaper kit 40 is provided.The kit can include a packaged diaper 10 in accordance with theembodiments discussed above and at least one diaper accessory 42. Acontainer 44 is also provided, in which each of the packaged diaper andthe diaper accessory are disposed. The diaper accessory can be a varietyof items, including, but not limited to, a diaper rash ointment or othermedicament, talcum powder/baby powder, a lotion, moist or dry wipes,cotton swabs, dirty diaper disposal bag, etc., as may be needed incaring for an infant or incontinent person, as will be known to oneskilled in the art of providing products for care of such persons. Inthe example embodiment shown, a packet of ointment 42A is included inthe kit, as are moist wipes 42B.

Thus, in one example, substantially all of the materials necessary forchanging a soiled diaper are provided in a small, space optimized kitthat can be easily carried or stored by a caretaker of an individualrequiring diapers. The kit can be advantageously used as a daily stapleof caretakers, or may be used in specialized circumstances such asoutdoor activities, travel, or business or recreational events away fromhome, or other situations in which space and convenience of carriage maybe of a premium. In such circumstances the caretaker may wish tominimize the number of articles needing carriage, and can advantageouslycarry one or two kits, as may be needed, and dispense with theconventional diaper bag that would otherwise have to be carried duringthe event or activity. Also, the reduced size of the present diaper kitcan allow one or more kits to be stored in an out-of-the-way location,such as a glove box of a car, and retrieved in “emergency” situations inwhich spare diapers were forgotten or consumed.

In another embodiment, the kit can be configured for use by anincontinent adolescent or adult. The kit can further include supplies totouchup stains on clothing. It can contain a small container of perfumeor cologne, a small container of odor reducing spray, or other itemswhich an incontinent adult may find needful and reassuring to carry, inaddition to supplies which customarily may be needed to change a diaper,including a clean diaper, wipes, and lotion, ointment or othermedicament, to name some examples.

As shown in FIG. 5, the diaper kit 40 can include a container 44 that issubstantially rectangular in shape. Such kits can be easily stacked andstored and will fit neatly into a pocket, purse or other baggage. Inanother embodiment, as shown in FIG. 6, the container 46 can besubstantially cylindrical in shape. In this embodiment, the diaper 12 bcan be formed in a cylindrical shape, or other shape to facilitatemaximum use of available space within the cylindrical container. Alsoincluded in the illustrated example shown in FIG. 6 are moist wipes 42Cwhich can be arranged in a disk-like or toroidal configuration fordisposal within the cylindrical container. With reference to FIG. 6A,the individual wipes 43 are accordion folded, then rolled about an axis45 transverse to the folds. A surprisingly large number of wipes thusconfigured can be fit into a surprisingly small space. In this manner, 6or 7 wipes or another selected number of wipes can be stored within thecontainer 46 to ensure ample supply.

In another aspect, illustrated by example in FIG. 7, an infant care kit49 can be provided which includes a diaper 50, one or more diaperaccessories 52 and a portion of infant food 54. An infant feeding bottleassembly is also provided having a hollow body 56 and a nipple fooddelivery portion 58 of the device couplable thereto. A cover 59 a or 59b can be provided, which keeps the feeder portion sanitary. This can bea throwaway tear-off film cover (e.g. 59 b) or a more conventionalreplaceable cap (e.g. 59 a). The feeding apparatus can be single use(i.e., disposable) or reusable. As shown, the diaper, diaper accessory,and portion of infant food can be disposed within the infant feedingassembly for convenient carriage. The infant feeding assembly can thusbe configured to: i) contain each of the diaper, diaper accessory andportion of infant food; and ii) upon removal of the diaper and diaperaccessory, receive the portion of infant food (and water, if applicable)within the hollow body and thereby enable delivery of the infant food toan infant via a food delivery device erstwhile acting as a container forthe kit. In one embodiment the nipple portion can be configured fordelivery of baby formula, and in another embodiment it can be configuredfor delivery of a flowable baby food such as a formula/cereal mixture,creamed vegetables or fruit, or the like. In one embodiment the babyfood can be in powder form, reconstituted by addition of water. Achemical warming pack (similar to or the same as a conventional handwarming pack) can be provided for use in warming the baby formula orother baby food.

In this example implementation, substantially all of the materialsnecessary to feed and change a diaper of an infant are provided in acompact, easily carried kit. A caretaker of the infant can use the kitto store the provided items, and when desiring to feed the infant, canprepare the portion of infant food and feed the infant with the infantfeeding assembly, shown in this embodiment as similar to a conventionalbaby bottle, but provided with a detachable bottom.

As shown in the illustrated example, the hollow body 56 of the feedingassembly 49 can be substantially cylindrical in shape, although othershapes are also contemplated, such as squared, triangular, and otherpolyhedral cross-sectional shapes. The portion of infant food caninclude a variety of foods suitable for consumption by infants,including powdered baby formula and condensed baby formula, freezedried, powdered, concentrated creamed vegetables and fruits and otherbaby foods, as well as cereal mixes, etc. A caretaker can easily removeall items from the feeding assembly, configure it for feeding, andreturning the portion of infant food (with water, as mentioned, ifnecessary, or other fluid which can be added to the infant food) and thefood can be fed to the infant via a food delivery device 58, aconventional baby bottle nipple in the illustrated embodiment.

In one embodiment, the feeding apparatus can include a double wallconfiguration to provide increased insulation so as to keep formula orother baby food at a desired temperature for a longer period of time. Tofacilitate this, or, to provide initial warming when hot potable wateris unavailable, a heat source 55, as mentioned, can also be disposedwithin the feeding assembly. The heat source can be configured toprovide heat for warming the portion of infant food, as well as anyfluid having been added to the infant food. In situations where it maybe necessary to add cold fluid such as milk or water to the infant food,the fluid and food can be warmed to a temperature well tolerated andmore acceptable to an infant. As mentioned, the heat source can be aconventional chemical heating apparatus, such as those producing anexothermic reaction when two or more separate materials are mixed, orare exposed to air. These can be packets of reactants in granular form,chemically activated gel heating sources, etc. The feeding apparatus canbe configured to cooperate with the heat source to heat the baby formulaor other food. In one embodiment, the kit can include an outer container(not shown) which is the outer wall of the double wall configurationmentioned. This can be a continuous wall, or can comprise vents (e.g. toexpose air to air-reactant heating pads). A mesh or other textile can beused as the material forming the outer containment in which the infantfeeding assembly is disposed. The outer container can be configured toreceive and protect the feeding assembly and can also encompass theheating source to maintain close contact between the heating source andthe hollow body 56.

In another embodiment, the heat source can be some other means ofproviding heat, for example provision of a metal outer sleeve, annularspace for water, and inner container for formula or food enabling use ofa cigarette lighter, a solar reflector or magnifier, or some otherhigher temperature heat source to heat the outer sleeve and still enablemore gentle warming of the contents of the inner sleeve. Such anarrangement would also facilitate rapid cooling of the outer sleeveafter removing the high temperature heat source so that it can be safelyhandled, enabling removal of the inner sleeve for feeding for example.

In another exemplary embodiment, shown in FIG. 8, a plurality of singleuse packaged diapers (not shown), or diaper kits 40, 40A can be providedpackaged together, each stacked vertically in a master container 60. Themaster container 60 can include a removable access panel (previouslyremoved in FIG. 8) through which one 40 of the plurality of containerscan be accessed. Providing for the removable access panel can be in oneof a variety of ways known to those in the art, including a perforatedremovable panel or hinged panel. A bottom 62 of the access panel can bedisposed in the master container 60 in a location vertically displacedfrom a bottom 64 of the master container by a distance substantiallyequal to a height “h” of the container. It has been found that havingthe last container to be used positioned below the access panel helpskeep the shape of the master container and improves appearance over thedispensing life of the product.

In this manner, as a kit is removed from the master container, the kitimmediately above the removed kit will fall into place to be easilyremovable from the master container. Notches 66 can be provided adjacentthe removable panel to enable easy withdrawal of kits through the panel.The master container 60 can be used to package and ship a number of kits40, and advantageously also used to dispense the kits at a retail centeror other point of sale. While the master container shown in FIG. 7 isconfigured to store and dispense 6 diaper kits, master containersconfigured to store and dispense fewer or more kits can also beprovided, and include two or more access panels disposed and oriented ina variety of locations on the master container.

Illustrated in FIGS. 9A and 9B is a diaper kit 68 in accordance withanother example implementation. In this embodiment, a diaper 70 andvarious diaper accessories 72 are contained within an encasement 74. Theaccessories can include baby ointment, baby wipes, powder, etc. asdiscussed above. In this example the accessories include baby ointment72A and wipes 72B. Other accessories can be substituted or additionallyincluded. Shown at 76 are seams formed in the encasement definingadjacent compartments that can each hold a different product. The seamscan separate products to enable differing treatment of the products inrelation to the encasement. For instance, diaper 70 can be disposed inthe encasement in a reduced volumetric configuration, as discussedabove, and the encasement can be evacuated and vacuum-sealed about thediaper. However, the baby ointment 72A can be vacuum sealed (if alreadypackaged in an impermeable containment without excess air) but need notbe vacuum sealed (indeed it may be difficult to do so if not alreadypackaged) in its corresponding compartment. Likewise the wipes 72 b arenot vacuum packed, but could be if previously enclosed in an impermeablecontainment without excess air.

While it may be desirable to vacuum-pack the diaper 70, and it ispossible to do so with some accessories, it may be the case that certainaccessories are not well suited to such an arrangement. For instance,with regard to the previously mentioned examples of ointment 72 a andwipes 72 not pre-packaged, baby wipes are often saturated or at leastmoisture-laden with a liquid cleaning compound similar in appearance tosoapy water, to aid in the cleaning process associated with changingdiapers. When subjected to a vacuum, the moisture may be withdrawn fromthe wipes, leading to poor performance of the wipes. In addition, ifundue moisture is removed during the vacuum process, the moisture mayinterfere with sealing the encasement once vacuum has been drawn,leading to premature breach of the encasement. The same applies to theointment, it would be likewise problematic to vacuum pack it, even moreso. Thus, for some products a vacuum seal may not be desirable ornecessary, and those products can be sealed in the encasement withoutbeing placed under vacuum.

To address these issues, the invention in one embodiment advantageouslyprovides a diaper kit that can include differently and variably treatedcompartments. In the example shown, the compartment containing thediaper 70 can be treated with a vacuum to aid in maintaining thevolumetrically reduced configuration of the diaper. The compartmentholding the ointment 72A may or may not be vacuum treated, as thesituation dictates. The compartment holding the wipes 72B can be simplysealed to retain the moisture in the wipes without drawing any moistureout with a vacuum process. Other compartments (not shown) can be treatedaccording to the product stored in each one.

In addition to the compartmentalized encasement shown in FIGS. 9A and9B, it is contemplated that in another exemplary embodiment of theinvention, shown in FIG. 9C, one can provide a diaper kit 68′ in whichall of the components of the kit are contained in an encasement 74′ andsealed under vacuum. For example, the diaper wipes 69 and/or otheraccessories can be pre-packaged in one or more casings 74″ with liquidand wipe material therein. In this way, both a diaper and one or moreaccessories, together forming a single use kit, can be integrallypackaged in one encasement 71′, and can all be accessed once theencasement has been breached.

With reference to FIGS. 10A through 10E, in one embodiment of theinvention the encasement in which the volumetrically reduced diaper isdisposed can contain the diaper without any substantial pressuredifferential acting upon the encasement. One illustrative process inwhich this can be achieved is illustrated in FIGS. 10A through 10E. Inthis embodiment, a “loose” diaper 80 is placed within a chamber 84B witha pair of encasement shells 82 disposed adjacent ends of the diaper.Rams 86 and 88 can be activated to compress the diaper into avolumetrically reduced configuration, as illustrated in FIG. 10B. Onceoptimal reduced volume is achieved, the diaper/shell assembly can bemoved adjacent a channel 85 defined between the chambers 84A and 84B, asillustrated in FIG. 10C.

Channel 85 can provide access to the diaper/shell assembly to enableattachment of a clamping strap 90 to the shells 82. The strap can aid inmaintaining relative position of the shells 82 after the pressureapplied to reduce the volume of the diaper is released. Thus, as shownin FIG. 10E, the rams 86, 88 and chambers 84 can be removed from contactwith the diaper, and the encasement maintains the diaper/shell assemblyin the volumetrically reduced configuration. In this manner, it is notnecessary to apply a vacuum to the encasement to create and maintain thevolumetrically reduced size of the diaper. In another embodiment, theencasement can be made air tight by application of the clamping strap,and thus a combination of differential pressure and hoop strength of theencasement can contain the diaper after the encasement expands to anequilibrium state.

As shown in FIGS. 11A and 11B, in one aspect of the invention, arestraint 92 can be provided in which the diaper 12 can be disposed asecond, reduced size, relative to a first, nominal size. The restraint92 can confine the diaper so that the diaper is retained in its reducedsize by the restraint and so that the diaper is returned to its nominalsize upon opening of the restraint. The restraint can be a strap or aseries of independent or interconnected straps, or, as shown in FIG.11B, the restraint 94 can include a webbed material. The restraint canbe formed of a material having sufficient strength to retain the diaper12 in the reduced size, but can be removed by a consumer to release thediaper into the first, nominal size, for example by exploiting anengineered weakness, as is conventionally provided in “tear-away”packaging closures.

An embodiment of a method for packaging a diaper very compactly byfolding and vacuum-sealing is shown in FIGS. 12-19. First, a bulkydiaper 6012 as shown in FIG. 12 is inserted into a U-shaped elongatedopen-ended forming jig 6014 as shown in FIG. 13 with the outside 6016 ofdiaper facing down into the jig and the inside 6018 of the diaper facingup and out of the jig. The ragged elastic banded edges of the diaper aretucked inward so as to obtain a smooth clean line exterior.

Thereafter, as shown in FIG. 14, a first end, such as end 6022, then isfolded inwardly covering a middle portion of the diaper, and then theother end 6026 is folded in over the first end 6022 and middle portionto form a rectangular shape of the diaper as shown in FIG. 15.

A spring-tensioned hand-clamp 6030 then is opened to receive thecompletely folded diaper between an upper flat rectangular jaw 6034 anda lower jaw 6036, as shown in FIG. 16. Furthermore, the clamp 6030 and ahand 6038 each compress the diaper 6028 as shown in FIG. 16.

The compressed, folded diaper 6028 then is inserted into an open end ofa pliable, resilient bag 6042. The diaper is inserted into the bag usingthe hand clamp 6030 and jig 6014 to facilitate the insertion as shown inFIG. 17, or, alternatively, as shown in FIG. 18, the compressed, foldeddiaper 6028 is directly inserted into the open-ended bag 6042 withoutthe jig.

The folded diaper 6028, fully inserted into the bag 6042 (FIG. 19), isthen placed onto the deck of a conventional vacuum-sealing machine, suchas a vacuum sealing-machine sold under the trademark SUPERVAC. The lidof the machine is fastened down and the vacuum-sealing machinevacuum-seals and cuts the bag to form a finished product as shown inFIG. 20.

The finished product is very firm and dense, looks like a taffy candybar, and is comparable in size to a candy bar. In one embodiment, thefinished product, i.e., a vacuum-sealed diaper package, measuresapproximately 1 inch by 2 inches by 1½ inches, and fits into a box forconvenient carrying within a purse.

Additionally, printing on the outside of the diaper is visible throughthe bag 6042 as shown, for example, in FIG. 20. Alternatively, theprinting on the outside of the diaper may be disposed within the foldeddiaper by first folding end 6026 inwardly covering a middle portion ofthe diaper and then folding the end 6022 in over the end 6026 and middleportion to form the rectangular shape of the diaper.

One or more embodiments of the invention relate to a method of packaginga diaper using a conventional vacuum-sealing machine. As shown in FIG.21A, a compressible absorbent diaper 104 is disposed within a flexiblesubstantially air impermeable encasement 102 and the unsealed encasement102 with the diaper 104 therein is then placed onto the deck 106 of thevacuum-sealing machine. The lid 108 of the machine is then lowered asshown in FIG. 21B establishing a seal with the deck to define a chamber110 with the unsealed encased diaper within the chamber. A pumpingsystem 112 then evacuates ambient air from the chamber 110 creating avacuum state within the chamber and within the interior space 103defined by the encasement with the diaper 104 therein. Sealing bars 114then seal the encasement as shown in FIG. 21C such that the interiorspace of the substantially air impermeable encasement 102 is completelysealed and such that the compressible absorbent diaper 104 is completelyenclosed within the sealed interior space 103. As shown in FIG. 21D,ambient air pressure is then restored to the chamber effecting apressure differential across the sealed encasement that acts upon theencasement to compress the compressible absorbent diaper 104 andmaintains the diaper in a reduced volume (FIG. 21D) that is less thanthe volume of the diaper at the time the encasement was sealed (FIG.21C, before ambient air pressure was restored to the chamber). As shownin FIG. 21E, the lid 108 is then raised and the vacuum-packed diaper 116is available for removal from the machine.

In addition to all of the foregoing, various preferred methods ofvacuum-packing a diaper also may include pressing at least a portion ofa vacuum-packed diaper and/or its encasement with a smooth surface inorder to achieve a smooth planar for aesthetic appeal. Indeed, as willnow be appreciated by the Ordinary Artisan in view of the foregoingdisclosure, a compressible article such as a diaper that isvacuum-packed will exhibit wrinkling and bunching. Furthermore, an airimpermeable encasement enclosing such an article will conform to anysuch bunching and wrinkling of the contained diaper as well as will beprone to forming its own undesirable wrinkles, puckers, and otherundesirable flaws during vacuum-packing. One or more preferredembodiments address this aesthetic concern by pressing at least aportion of the diaper and/or encasement in order to flattening a face ofthe diaper and/or encasement. The pressing may occur beforevacuum-packing, after vacuum-packing, during vacuum-packing, or anycombination thereof.

For example, in FIGS. 13-15, portions of the outside of the diaper arepressed by the floor of the U-shaped jig as the diaper is foldedlyreduced in the jig. For further example, as shown in FIG. 16, prior tobeing disposed within an encasement, the diaper is pressed within theclamp 6030 between the flat jaws thereof that comprise essentiallyplanar surfaces. As further shown in FIG. 18, the clamp can be used topress at least a portion of the diaper while the diaper is beinginserted into and/or is otherwise disposed within an encasement.

In another example, as shown in FIG. 22, a vacuum-packed diaper 122 ispressed between the essentially planar surface 126 of a conveyor belt128 and the essentially planar surface 130 of a press 132. Avacuum-packed diaper 120 prior to pressing appears wrinkled with creasesin the transparent material of the encasement that tend to distort orblock view of the diaper within, as shown in FIG. 22. In contrastthereto, a vacuum-packed diaper 124 after pressing exhibits anaesthetically pleasing appearance with indicia 134 printed on the diaperbeing visible through a substantially smooth planar face of thetransparent material of the encasement. Note that in this example, theencasement of the vacuum-packed diaper is pressed by the conveyor beltand the press providing a generally smooth planar face in the top aswell as the bottom of the encasement. Note furthermore that theencasement is formed of a material that is at least somewhat flexible,whereby the diaper within the encasement is pressed by the conveyor beltand press, too, resulting in generally smooth planar faces in the topand bottom of the diaper.

Another example of pressing is shown in FIG. 23, wherein a vacuum-packeddiaper 138 is pressed between the essentially planar surfaces of a pairof presses 142. A vacuum-packed diaper 136 prior to pressing appearswith wrinkles and creases whereas a vacuum-packed diaper 140 afterpressing assumes a generally smooth planar appearance believed to beaesthetically pleasing. As in the previous example, the vacuum-packeddiaper 140 is substantially flattened and the encasement includesgenerally smooth oppositely facing planar faces 144,146.

In yet other examples of pressing shown in FIGS. 24-26, vacuum-packeddiapers are pressed with the generally smooth circular surfaces ofrollers. In particular, in FIG. 24, an upper surface 152 ofvacuum-packed diaper 150 is pressed by a roller 154 as the diaperprogresses along a conveyor belt 156. In FIG. 25, respective upper andlower surfaces 158 a and 158 b of a vacuum-packed diaper 162 are pressedby respective opposing rollers 164 a and 164 b. In FIG. 26, a first pairof opposing rollers 166 a,166 b is sequentially arranged with a secondpair of opposing rollers 168 a,168 b such that vacuum-packed diapers 170are progressively smoothed in passing sequentially through the rollerpairs. Moreover, the rotational speed of opposing rollers 168 a, 168 bmay be greater than the rotational speed of opposing rollers 166 a, 166b such that the encasement and/or diaper therein are subjected to slighthorizontal forces in the direction 172 of travel of the conveyor belt,thereby further removing or pulling out wrinkles in the encasementand/or diaper.

Also in addition to all of the foregoing, various preferred embodimentsmay include a compressible absorbent diaper that is configured anddisposed within an encasement, a portion of which is transparent suchthat indicia on the diaper may be viewable there through.

The indicia on the diaper may be printed and, as shown in FIGS. 27-37,the indicia may include animal characters for amusement of a child. Theindicia also may be associated with a particular manufacturer ordistributor of diapers and, thus, constitute a trademark. In otherexemplary instances, the indicia may include brand identifiers, sizinginformation, or any other information that characterizes or identifiesthe diaper to a consumer. Indeed, the indicia may provide recognition ofthe article that is vacuum-sealed within the encasement, which can beespecially helpful in determining the size of the diaper, since theactual size of the diaper will be difficult to judge based on the sizeof the vacuum-packed diaper itself.

In yet other examples, especially with regard to adult diapers, indiciaof the diaper may comprise or contribute to a disguise of the diaper,thereby reducing the ability of another party to readily identify thediaper upon a glancing view or casual viewing.

In accordance with various preferred embodiments of the invention,configuring a diaper for viewing of indicia disposed thereon may entailtucking and/or folding of the diaper for disposition within anencasement. As used herein, “tucking” refers to the tucking in of top,bottom, and/or side margins of a diaper, which margins typicallyconstitute an elastic band, tabs, and the like. Tucking of the fullyextended diaper shown in FIG. 27, for example, can result in an unfoldedrectangular configuration of the diaper as shown in FIGS. 29A and 29B.

A preferred method of tucking and folding a diaper will now be describedwith reference to FIGS. 27-30.

Turning to FIG. 27, a fully extended diaper 200 includes indicia 202printed on the front portion of an outer surface 206 of the diaper.Thus, when the diaper of FIG. 27 is worn, the indicia 202 is situatedproximal the groin area and navel of the wearer.

In accordance with the described preferred embodiment, end margins 208of the diaper 200 that are visible in FIG. 27 are tucked along crosswiseaspects of the diaper, whereby the end margins are disposed underneaththe diaper as shown in FIG. 28. Side margins 210 that are visible inFIG. 28 also are tucked along a lengthwise aspects of the diaper,whereby the side margins are disposed underneath the diaper as shown inFIGS. 29A-29B. By tucking the side and end margins, an unfolded,generally rectangular configuration of the diaper is obtained as shownin FIG. 29A-29B. It should be noted that the tucking of end marginsand/or side margins is optional in obtaining a generally rectangularconfiguration but is preferred due to the benefit of aestheticpresentation of the indicia. Furthermore, it should be appreciated bythe Ordinary Artisan that, as shown, the tucking of end margins and sidemargins to obtain the unfolded rectangular configuration shown in FIGS.29A-29B does not include folding of the absorbent area or core 211 ofthe diaper, which comprises the portion of the diaper that is intendedto perform the absorbing function.

From the rectangular configuration shown in FIGS. 29A-29B, the diaper isfolded along a centered, crosswise aspect to obtain a folded rectangularconfiguration in which the indicia 202 printed on the diaper is moreprominently displayed, such as shown in FIG. 30. Furthermore, it will beappreciated that, in folding the diaper to arrive at the configurationshown in FIG. 30, a fold line necessarily will extend through theabsorbent core 211 of the diaper.

The diaper next is disposed within an air and moisture impermeableencasement and vacuum-sealed in accordance with one or more methods ofthe foregoing disclosure for vacuum-packing diapers. The resultingvacuum-packed diaper is illustrated in FIGS. 31A-31B, wherein the diaperof FIG. 30 has been sealed within encasement 212 having at least aportion 214 thereof that is transparent. The diaper, tucked and foldedas here described, is viewable through the transparent portion 214 ofthe encasement and, particularly, the indicia 202 printed on the outersurface of the diaper is readily viewable through the transparentportion of the encasement. Additionally, notches 218 are formed alongouter edges of the encasement 212 to aid in opening the encasement.

Another exemplary preferred embodiment is illustrated in FIGS. 32-33. Inthis case, a fully extended diaper 220 is shown in FIG. 32 with indicia222 printed on the front outer surface 226 of the diaper. Afterobtaining an unfolded rectangular configuration similar to that of FIGS.29A-29B by tucking end and side margins, the diaper 220 is twice foldedalong crosswise aspects (as illustrated in FIGS. 14-15) to obtain afolded rectangular configuration, and then the folded diaper is disposedand vacuum-sealed within a transparent encasement 228 resulting in thevacuum-packed diaper of FIGS. 33A-33B.

As shown in FIG. 33B, the crosswise folds 230 define a first end portion232 of the diaper folded within the configuration, a second end portion234 folded over the first end portion 232, and a medial portion 236joining the first and second end portions. The first end portion 232folded within the configuration is disposed between the second endportion 234 and the medial portion 236. The diaper, tucked and folded ashere described and shown in FIGS. 33A-33B, is viewable through theencasement and, particularly, the indicia 222 printed on the outersurface of the diaper along the second end portion 234 is readilyviewable through the transparent encasement and enjoys a prominent areaof the viewable top surface of the diaper.

Another exemplary preferred embodiment is illustrated with reference toFIGS. 34-35. In FIG. 34, a fully extended diaper 240 is shown withindicia 242 printed on the outer surface 246 of the diaper. In thisexample, after obtaining an unfolded rectangular configuration similarto that of FIGS. 29A-29B through tucking end and side margins, thediaper 240 is twice folded along crosswise aspects to obtain a foldedrectangular configuration, and then the diaper is disposed andvacuum-sealed within a transparent encasement 248 resulting in thevacuum-packed diaper of FIGS. 35A-35B. As shown in FIG. 35B, thecrosswise folds 250 define a first end portion 252 of the diaper, asecond end portion 254 folded over the first end portion 252, and amedial portion 256 joining the first and second end portions. Thediaper, tucked and folded as here described and shown in FIGS. 35A-35B,is viewable through the encasement 248 and, particularly, the indicia242 printed on the outer surface of the diaper along the medial portion256 is viewable through the transparent vacuum-sealed encasement 248.

Unlike the exemplary preferred embodiment of a vacuum-packed diaperillustrated in FIGS. 33A-33B, the indicia of the vacuum-packed diaperillustrated in FIGS. 35A-35B is intended primarily for viewing in thevacuum-packed configuration as opposed to viewing when the diaper isworn, as the indicia when worn generally will face the feet of thewearer. The indicia of the vacuum-packed diaper illustrated in FIGS.35A-35B is readily visible in the vacuum-packed configuration as well aswhen the diaper is worn.

In yet another example, a diaper 260 and diaper-changing accessoriessuch as wipes 270 are disposed within a transparent encasement 268. Thewipes 270 preferably are, themselves, prepackaged within a moistureimpermeable encasement to avoid moisture from the wipes 270 from beingabsorbed by the diaper 260.

In this example, wherein the diaper 260 is tucked and folded in similarmanner to that of the diaper of FIG. 33B, the wipes 270 are disposedbelow the medial portion 266 of the diaper within the encasement. Thediaper 260, tucked, folded and disposed within the encasement 268 withthe wipes 270 as shown in FIGS. 36A, 36B, and 37, is at least partiallyviewable through the encasement and, particularly, the indicia 262printed on the outer surface of the diaper along the end portion 264 isviewable through the encasement 268. The wipes 270 are arranged withinthe encasement so as not to obstruct the view through the encasement ofthe indicia printed on the diaper.

In addition to the arrangement of the diaper 260 and wipes 270 withinthe encasement 268, it should also be noted that notches 272 also areformed along outer edges of the encasement 268 as shown in FIGS. 36A,36B, and 37 to aid in opening the encasement. Furthermore, a weakenedline 274 in the encasement 268 is formed in the material of theencasement as an engineered weakness to further aid in opening theencasement by providing a “tear-away” portion 276 of the encasement.

While many embodiments of the invention relate generally tovolumetrically reducing absorbent articles, especially byvacuum-packing, for convenience in carrying and storing of the absorbentarticles by consumers, such absorbent articles can be conveniently,comfortably, and discreetly concealed, carried and stored. This isespecially beneficial to adult consumers in the incontinent adultmarket, who may want to avoid public knowledge of their use of certainabsorbent articles. Such absorbent articles for incontinent adultscomprise, for example, diapers, underpants, pant liners, feminine pads,and male pouches.

Unfortunately, simply concealing and carrying of a volumetricallyreduced absorbent article does not preclude revelation of the articleupon casual observance such as, for example, when the article isaccidentally spilled from a purse or bag along with other contents, orwhen the article falls from a pocket during physical activity. Suchtimes can be embarrassing for adult consumers.

To address such embarrassing incidents particular embodiments of theinvention relate to disguisedly packaged absorbent articles. Accordingto such particular embodiments, discretion and concealment is attainedby way of a disguisedly packaged absorbent article having an outwardappearance capable of deceiving a casual observer. In this regard, adisguisedly packaged absorbent article may be casually observed withoutbeing correctly identified. That is, a disguisedly packaged absorbentarticle preferably hides in plain sight.

Turning to the drawings, an exemplary package 300 comprising adisguisedly packaged diaper that has been volumetrically reduced isshown in FIGS. 38-39. Preferably, the diaper is disposed withinencasement 304 in the exemplary configuration 306 shown in FIG. 40,which comprises at least two folds that enable the diaper to obtain anoutward shape similar to that of a filled candy bar like a “Snickers”™candy bar. Furthermore, the encasement 304 preferably has disguisingindicia 302 printed thereon that facilitates the deception of anunknowing observer with regard to the actual contents of the package300. In this respect, the package 300 preferably visually resembles awrapped candy bar in size, shape, and/or indicia thereon. The printedindicia illustrated (“CANDY BAR”) is intended to represent any indiciathat may suggest that the package is a wrapped candy bar.

In this exemplary package 300, the absorbent article preferably comprisea diaper that is vacuum-sealed within the encasement 304 in accordancewith preferred embodiments discussed above.

Another exemplary package 320 comprising a disguisedly packaged diaperthat has been volumetrically reduced is shown in FIG. 41. In thisexample, the diaper 326 is disposed within a first encasement 324 in avolumetrically reduced configuration as shown in FIG. 42. Thevolumetrically reduced configuration of the diaper 326 preferablycomprises at least one crosswise fold obtaining an outward shape likethat of a planar (non filled) candy bar like a “Mr. Goodbar”™ candy bar.A secondary encasement 328 (FIG. 41) is wrapped and folded about thefirst encasement 324 and has disguising indicia 322 printed thereon thatfacilitates the deception of an unknowing observer with regard to theactual contents of the package 320. In this respect, the package 320preferably visually resembles a wrapped candy bar in size, shape, and/orindicia thereon. The printed indicia illustrated (“CANDY BAR”) isintended to represent any indicia that may suggest that the package is awrapped candy bar.

In this exemplary package 320, the diaper preferably comprise a diaperthat is vacuum-sealed within the encasement 324.

Yet a third exemplary package comprising a disguisedly packaged diaperthat has been volumetrically reduced is shown in FIGS. 43-44. In thisexample, the volumetrically reduced diaper 342 is disposed within aprimary encasement 346. The primary encasement 346 then is disposedwithin a secondary encasement forming the package 340. Furthermore, thesecondary encasement includes disguising indicia that facilitates thedeception of an unknowing observer with regard to the actual contents ofthe package 340. In this respect, the package 340 preferably visuallyresembles a pack of cigarettes in size, shape, and/or indicia thereon.The printed indicia illustrated (“CIGARETTES”) is intended to representany indicia that may suggest that the package 340 is a pack ofcigarettes.

In this exemplary package 340, the diaper preferably comprise a diaperthat is vacuum-sealed together with accessories 344, such as wipes,within the encasement 324.

Still yet another exemplary package comprising a disguisedly packageddiaper that has been volumetrically reduced is illustrated by FIGS.45-49. In this example, a volumetrically reduced diaper 422 is disposedwithin an encasement 424. The encasement 424 comprises a pair ofopposing shells 426,428 and a clamping band 430. As illustrated by FIGS.48-49, the clamping band 430 aids in maintaining the relative positionsof the shells and keeping the volumetrically reduced diaper 422contained between the shells. In particular, respective extensions432,434 of the shells 426,428 are received within channels (not shown)of the clamping band 430 such that the clamping band 430 slides over theextensions 432,434 for retention therein.

The diaper 422 is disposed within the encasement 424 in a volumetricallyreduced configuration by way of, for example, the process illustrated inFIGS. 10A-10E discussed above, and may or may not include vacuum-packingof the absorbent article. The diaper 422 is removed from the encasement424 by removing the clamping band 430 from and separation of the shells426,428.

The encasement and, in particular, the shells 426,428 include an outwardappearance similar to that of a mobile telephone in size, shape, and/orindicia thereon. For example, indicia 438 on shell 428 resembles thekeys of a keypad. The area of shell 428 comprising the buttons furthermay be raised or may comprise components of a different material inorder to give a convincing appearance of a keypad. A screen further maybe imitated by the shape and/or indicia of the shell 426. Additionally,the shell 426 includes a protuberance resembling an antennae.

Another exemplary package comprising a disguisedly packaged diaper thathas been volumetrically reduced is shown in FIGS. 50-52. In thisexample, the diaper 458 (FIG. 52) is disposed within an encasement 452.The encasement 452 comprises a pair of separable opposing shells454,456. As illustrated by FIG. 52, the shells keep the volumetricallyreduced diaper 458 contained therebetween and are separable for removingof the diaper 458 from the package. Preferably, the shells 454,456 snapinto interlocking engagement with one another and can be separated byselectively applied force at the areas of the interlocking engagement.Moreover, such type of engagement is conventional and therefore is notfurther discussed herein.

The diaper 458 is disposed within the encasement 452 in a volumetricallyreduced configuration by way of, for example, the process illustrated inFIGS. 10A-10E discussed above, and may or may not includevacuum-packing.

The encasement 452 and, in particular, the shells 454,456 include anoutward appearance similar to that of a personal pager in size, shape,and/or indicia thereon. For example, indicia on and or the shape ofshell 456 exhibits the resemblance of keys and a screen of a pager.Additionally, the shell 454 includes a belt clip 462 that resembles thebelt clip of a pager.

While many embodiments relate generally to volumetrically reducedabsorbent articles that can be conveniently carried and stored,particular embodiments relate to volumetrically reduced diapers forchildren wherein a diaper is contained within a child's toy. In thisrespect, the toy comprises a container for the diaper. By packaging adiaper within a toy, a toy is conveniently on hand at the time of adiaper changing for amusement of the child before, during, and/or afterthe diaper changing.

An exemplary embodiment of a toy container in accordance with thisaspect of the invention is illustrated by FIGS. 53-54 and comprises adoll 500 resembling a kangaroo in which a volumetrically reduced diaper502 is disposed. Each of rigid upper and lower body portions 506,508 ofthe doll 500 defines an internal compartment 504 for receivingrespective portions of the diaper 502. The upper portion 506 and lowerportion 508 are separable for removal of the diaper 502.

In this exemplary embodiment, the volumetrically reduced diaper 502 isdisposed within the doll 500 in a rolled, cylindrical configuration thatcorresponds to and fits within the cylindrical compartments 504 of theupper and lower portions 506,508. In some embodiments, the diaper 500 isvacuum-sealed within an encasement and then disposed within the doll500; in other embodiments, the diaper 500 disposed within the doll 502is not vacuum-sealed. A diaper also may be disposed within dolls inother configurations, especially if the compartments within the otherdolls have other than cylindrical configurations. Thus, for example, avolumetrically reduced diaper may include a rectangular configurationfor disposition within a rectangular compartment of a doll. Anotherexemplary embodiment comprising a doll 520 that also resembles akangaroo is illustrated by FIGS. 55-56. In this example, avolumetrically reduced diaper 522 is disposed within a cylindricalcompartment 524 defined by a semi-soft, integral body portion 526 of thedoll 520. The compartment 524 is accessible through an opening locatedunderneath the body portion 526 of the doll 520. The opening is closedto contain the diaper 522 within the doll 520 using closure element 528,which closure element may comprise, for example, a friction-fit plug, athreaded screw cap, or a lid that snaps into place. As with the doll500, the diaper 522 in doll 520 is vacuum-sealed in certain embodimentsand is not vacuum-sealed in other embodiments, as desired.

Another exemplary embodiment of a toy in which a volumetrically reduceddiaper is disposed comprises a toy ball 540 as illustrated by FIGS.57-60. In this embodiment, the ball 540 includes a rigid top portion 546that is connected to a rigid bottom portion 548 by a hinging member 544such that the top portion 546 moves about the hinging member 544relative to the bottom portion 548. Thus, the top and bottom portions546,548 are movable between a closed position, as shown in FIG. 58, andan open position, as shown in FIG. 59. When the ball 540 is in theclosed position, closure tab 550 keeps the top portion 546 engaged withbottom portion 548 for containment of the diaper 542. The ball 540 isopened by applying inward pressure adjacent the closure tab 550 forrelease of the top portion 546 from the bottom portion 548. The diaper542 is freely removable from the ball 540 when in the open position, andthe diaper 542 is shown in FIG. 60.

In this exemplary embodiment, the volumetrically reduced diaper 542 isdisposed within the ball 540 in a rolled, cylindrical configuration thatcorresponds to and fits within internal compartments of the top andbottom portions 546,548 of the ball 540. In some embodiments, the diaper542 is vacuum-sealed within an encasement and then disposed within theball 540; in other embodiments, the diaper 542 disposed within the ball540 is not vacuum-sealed. A diaper also may be disposed within toy ballsin other configurations, especially if the compartments within the otherballs have other than cylindrical configurations. Thus, for example, avolumetrically reduced diaper may include a rectangular configurationfor disposition within a rectangular compartment of a toy ball.

Yet another exemplary embodiment of a toy in which a volumetricallyreduced diaper is contained comprises a toy rocket 570 as illustrated byFIGS. 61-62. The toy rocket 570 includes a cylindrical sleeve 574 thatdefines a compartment in which a volumetrically reduced diaper 572 iscontained, as shown in FIG. 62. Furthermore, the toy rocket 570 includesa removable cap 576 that serves as the nose of the toy rocket 570 forfull enclosure and containment of the diaper 572 within the sleeve 574.The volumetrically reduced diaper 572 is shown in FIG. 63 in thecylindrical configuration in which it is disposed within the sleeve 574of the toy rocket 570. The cylindrical sleeve 574 may be flexible or,alternatively, the sleeve 574 may be flexible with the volumetricallyreduced diaper 572 disposed therein providing a degree of rigidity tothe sleeve 574 and overall toy rocket 570.

Still yet another exemplary embodiment of a toy in which avolumetrically reduced diaper 582 is disposed comprises a toy car 580 asillustrated by FIGS. 64-66. Like the toy ball 540 illustrated by FIGS.57-60, the toy car 580 includes a rigid top portion 586 that isconnected to a rigid bottom portion 588 by a hinging member 584 suchthat the top portion 586 moves about the hinging member 584 relative tothe bottom portion 588. Thus, the top and bottom portions 586,588 aremovable between a closed position, as shown in FIGS. 64-65, and an openposition, as shown in FIG. 66. When the toy car 580 is in the closedposition, closure tab 590 keeps the top portion 586 engaged with bottomportion 588 for containment of the diaper 582. The toy car 580 is openedby applying inward pressure adjacent the closure tab 590 for release ofthe top portion 586 from the bottom portion 588. The diaper 582 isfreely removable from the toy car 580 when in the open position.

In this exemplary embodiment, the volumetrically reduced diaper 582 isdisposed within the toy car 580 in a configuration that corresponds toand fits within internal compartments of the top and bottom portions586,588 of the toy car 580. The particular configuration of thevolumetrically reduced diaper is illustrated in FIGS. 67-68 and, as willbe apparent, resembles the shape of the top and bottom portion 586,588of the toy car 580. In some embodiments, the diaper 582 is vacuum-sealedwithin an encasement such as a flexible bag and then disposed within thetoy car 580; in other embodiments, the diaper 582 disposed within thetoy car 580 is not vacuum-sealed. A diaper also may be disposed withintoy cars in other configurations, especially if the compartments withinthe other toy cars have other than cylindrical configurations. Thus, forexample, a volumetrically reduced diaper may include a cylindrical orrectangular configuration for respective disposition within acylindrical or rectangular compartment of a toy car.

Additionally, an exemplary method of making the volumetrically reduceddiaper 582 of the exemplary embodiment of FIGS. 67-68 is illustrated inFIG. 69. In this regard, a mold 592 having a configuration matching thatof the compartment of the top portion 586 of the toy car 580 is forciblypressed onto the top of diaper 594 resulting in diaper 582. Furthermore,diaper 594 preferably is vacuum-sealed within an air impermeableencasement (not illustrated) during the pressing process, such thatdiaper 582 retains its molded configuration for later disposition withinthe toy car 580. This preferably is accomplished by carrying out thepressing of the mold 592 onto the diaper 594 within a vacuum chamber(represented by the rectangular box in FIG. 69). Alternatively, forexample, a diaper first may be vacuum-packed and then forciblyconfigured into the desired configuration for disposition within a toy.

Any of the foregoing toy containers may be packaged for individual saleto consumers or packaged together for sale to consumers; however, inaccordance with an aspect of the invention, such toy containers furthermay be sold in conjunction with packages of conventional diapersarranged together in their nominal configuration, with one or more toycontainers being disposed in such packages as “prizes” similar inmarketing theory to those prizes found in “Crackerjack”™ boxes orprovided in kids meals at fast food restaurants.

Still yet another aspect of the invention relates to refills for suchtoy containers. In this respect, once a volumetrically reduced diaperhas been removed from its toy container and used, a consumer may preferto reinsert another volumetrically reduced diaper into the toy containerat a later time. Accordingly, in this aspect of the invention, packagesof individual, volumetrically reduced diapers are sold as refills forsuch toy containers.

In addition to the above disclosure, another aspect of the inventionrelates to vending and, in particular, to vending systems and machinesfor dispensing volumetrically reduced absorbent articles such asvacuum-packed diapers. Indeed, it may be particularly beneficial toinclude such a vending machine in conjunction with each courtesy babychanging station commonly found in public restrooms of commercialestablishments.

An exemplary vending machine 700 is shown in FIGS. 70-71. Vendingmachine 700 includes a structural housing 702 and multiple, slotted,currency-receiving slides 704 extending from an anterior vending face706 of the vending machine 700. The vending machine 700 further includesviewing windows 705 for presentation of selectable products that arerespectively dispensed upon actuation of the currency-receiving slides704. Each product is dispensed for a predetermined currency amount thatis optionally indicated in the respective viewing window 705 or on therespective currency-receiving slide 704.

As shown in FIG. 71, the exemplary vending machine 700 contains, inassociation with each currency-receiving slide, a vertical stack 708 ofproducts 710. In selecting and purchasing a product, a consumer placescurrency 712 into a particular currency-receiving slide 704, actuatesthe slide by pressing the slide inwardly in the direction of arrow 714,and receives 716 one of the selected products 718 associated with theparticular currency-receiving slide 704 through dispensing slot 712(FIG. 70).

As further shown in FIG. 71, the exemplary vending machine 700preferably comprises posterior access panels for secure access by avendor or operator of the vending machine 700. In this respect, thevending machine 700 extends through a wall 720 (FIG. 71) in which it ismounted. Consequently, a vendor may securely restock (726) the verticalstack 708 with additional products 728 through a product access panel730. Furthermore, a vendor may securely collect (732) deposited currency734 through a currency access panel 736.

In accordance with this aspect, the products 708 dispensed by thevending machine 700 include individually packaged volumetrically reducedabsorbent articles, such as diapers. The products 708 additionally mayinclude multi-packs of volumetrically reduced absorbent articles such asdiapers; kits including volumetrically reduced absorbent articles suchas diapers, toys containing volumetrically reduced absorbent articlessuch as diapers, and disguisedly packaged absorbent articles. Moreover,products 708 that do contain volumetrically reduced diapers eachpreferably contains one of the many embodiments of an individuallyvacuum-packed diaper as previously disclosed herein.

It is to be understood that the above referenced arrangements areillustrative. It will be apparent to those of ordinary skill in the artthat numerous modifications can be made without departing from theprinciples and concepts of the invention.

Turning now to FIGS. 72-103, a combination package for retail sale(hereinafter “COMBO PACK”) includes reduced and non-reduced articlesand, in particular, reduced diapers and non-reduced diapers. Reduceddiapers are provided within restraining encasements for convenientcarrying. A reduced diaper, once removed from the restrainingencasement, is capable of being expanded to a non-reduced configurationfor use. Each diaper preferably is reduced by being vacuum-packed. ACOMBO PACK may include any number of vacuum-packed and non vacuum-packeddiapers. The foregoing will be more readily understood uponconsideration of the drawings and the following detailed description.

An embodiment of a COMBO PACK of absorbent articles comprising diapersis show in FIG. 72. The COMBO PACK includes a first package and a secondpackage removably attached together by an adhesive or other attachment.The first package contains non vacuum-packed diapers, and the secondpackage contains one or more individually vacuum-packed diapers. In FIG.73, a vacuum-packed diaper is visible through a tear-away portion of thesecond package. In FIG. 74, the vacuum-packed diaper is shown removedfrom the second package.

The vacuum-packed diaper in FIGS. 73 and 74 is contained in atransparent restraining encasement. The vacuum-packed diaper is foldedwithin the restraining encasement such that graphical indicia of thearticle are visible through the encasement. Thus, the graphicalcharacters printed on the diapers are prominently displayed through thetransparent encasement in which the diaper is vacuum packed. Preferably,the diaper is specifically configured during vacuum-packing for suchprominent display.

The encasement restrains the vacuum-packed diaper in a configurationthat is reduced in area and volume. In the example shown in FIGS. 73 and74, the reduced diaper is folded and contained in an encasement that isvacuum-sealed. In other examples (not shown), diapers are retained inreduced configurations that are folded, compressed, and folded andcompressed, all with and without vacuum-sealing. Diapers that arereduced and restrained in encasements with and without vacuum-sealingare described above in connection with FIGS. 1-71 and below inconnection with FIGS. 104-129.

In FIG. 75, another embodiment of a COMBO PACK includes a first packageand a transparent restraining encasement that contains a vacuum-packeddiaper. The encasement is attached to the first package by an adhesiveor other similar attachment means.

In FIGS. 76-77, yet another embodiment of a COMBO PACK includes avacuum-packed diaper and a number of non vacuum-packed diapers allcontained within a first package. The vacuum-packed diaper is containedwithin a restraining encasement that is placed within the first packagetogether with the non vacuum-packed diapers. In FIG. 78, thevacuum-packed diaper within its restraining encasement is shown removedfrom the first package and placed alongside a non vacuum-packed diaperthat also has been removed from the first package. The vacuum-packeddiaper, once removed from the restraining encasement, is capable ofbeing expanded to a non-reduced configuration for use similar to theconfiguration of the non vacuum-packed diaper shown in FIG. 78.

In FIG. 79, yet another embodiment of a COMBO PACK includes a number ofnon vacuum-packed diapers and a “bi-pack” or “twin pack” ofvacuum-packed diapers within a first package. The bi-pack consists oftwo diapers that have been vacuum packed together within the sameencasement. Each of the vacuum-packed diapers includes a “C” shapedfolded configuration.

In FIG. 80 an opened first package containing a number of nonvacuum-packed diapers is shown with several examples of a vacuum-packeddiaper within a restraining encasement. A COMBO PACK according to theinvention may include any number of vacuum-packed diapers and any numberof non vacuum-packed diapers. In some embodiments, a COMBO PACKaccording to the invention includes more non vacuum-packed diapers thanvacuum-packed diapers.

Thus, for example, in a particular embodiment, a COMBO PACK includesseveral dozen non vacuum-packed diapers and one vacuum-packed diaper. Inanother particular embodiment, a COMBO PACK includes several dozen nonvacuum-packed diapers and two vacuum-packed diapers in the sameencasement. In yet another particular embodiment, a COMBO PACK includesseveral dozen non vacuum-packed diapers and six individuallyvacuum-packed diapers. In yet other particular embodiments (shown insubsequent figures), vacuum-packed diapers are provided in containersthat further include such items as diaper-changing accessories, babyfeeding supplies, and disposal bags, thereby forming kits.

In FIG. 81, an embodiment of a COMBO PACK includes, within a firstpackage, a number of non vacuum-packed diapers and a second package. Oneor more individually vacuum-packed diapers are contained within thesecond package.

In FIGS. 82 and 83, an embodiment of a COMBO PACK includes first packagethat contains a number of non vacuum-packed diapers and a vacuum-packeddiaper contained within a restraining encasement that is removablyattached to the first package by a peel-away film.

In FIG. 84, a COMBO PACK is shown that includes a vacuum-packed diaperand a number of non vacuum-packed diapers within a first package. Thevacuum-packed diaper is contained within a restraining encasement thatis placed within the first package.

In FIG. 85, a COMBO PACK is shown that includes a number of individuallyvacuum-packed diapers disposed within a dispenser that, together with anumber of non vacuum-packed diapers, is disposed within a first package.In FIGS. 86-87 the dispenser is shown removed from the first package. Inthis embodiment, the dispenser contains six individually vacuum-packeddiapers and is referred to as a “6-Pack”. An opening is defined in thedispenser for convenient removal of the individually vacuum-packeddiapers within the dispenser, as shown in FIG. 87. Furthermore, eachvacuum-packed diaper is disposed within an individual box that itself isremovable from the dispenser, as shown in FIG. 88. The dispenserprovides convenience to the consumer in that the first package containsnon vacuum-packed diapers and vacuum-packed diapers with thevacuum-packed diapers being conveniently grouped together within thedispenser for wholesale removal from the first package. The dispenserthen can be placed wherever a supply of individually vacuum-packeddiapers is preferred by the consumer, such as in a vehicle or travelbag. According to various embodiments, a first package can contain anynumber of non vacuum-packed diapers and any number of dispensers ofindividually vacuum-packed diapers, and each dispenser can contain anynumber of vacuum-packed diapers.

Furthermore, as shown in FIGS. 86-88, each box containing avacuum-packed diaper further comprises a kit, in that the box alsocontains one or more accessories for changing of a diaper. The kitcontains a reduced diaper and, optionally, any or all of, for example,an ointment, a soft tipped swab for cleaning or application, acomforting powder, cleaning articles, and a disposal container. Moreparticularly, as shown in FIG. 92 by way of a descriptive label printedon the box, the kit may contain a reduced diaper, Desitin®, one or moreQ-Tip™ swabs, baby powder, disposable wipes, and a sealable disposalbag. Other kits may contain other items useful to the consumer, such asodor control articles like solutions or sprays. Yet other kits mayinclude feeding-related items, such as infant formula, a feeding bottleand nipple, baby food, a utensil such as a feeding spoon, and a heatsource for warming the baby food or formula.

Rather than being disposed within a dispense, a kit itself may bedisposed with non vacuum-packed diapers in the first package, as shownin FIGS. 89-91.

Other examples of a kit including a box having a vacuum-packed diaperand one or more accessories are shown in FIGS. 93-95. Examples of a kitincluding a flexible bag having a vacuum-packed diaper and one or moreaccessories is shown in FIGS. 96-101. One or more of any of these kitsmay be combined with a first package of non vacuum-packed diapers.

FIG. 102 illustrates a preferred arrangement for disposing two 6-Packdispensers in a package with non-vacuum-packed diapers. In this regard,a 6-Pack dispense is shown on either end of, and sandwichingtherebetween, a row or column of non vacuum-packed diapers. Thisarrangement may be disposed within a first package to form a COMBO PACK.A dispenser as shown located at either end of the package will provide adegree of structural rigidity at the ends of the COMBO PACK, especiallyat the corners.

Finally, FIG. 103 illustrates a COMBO PACK at the center (identified bythe trademark “PAMPERS”) in which one or more vacuum-packed diapers aredisposed in conjunction with non vacuum-packed diapers. Furthermore, oneor more of the vacuum-packed diapers preferably is contained within asecondary packaging or container having a form factor represented by anyone of the various possibilities shown in FIG. 103, which include: aplastic toy car; a stuffed animal such as a kangaroo (“Joey”); acylindrical container or tube; a baby bottle; and a hard case clam-shellcontainer. Moreover, the secondary packaging or container having thevacuum-packed diaper may include one or more additional accessoriesthereby to form a kit as shown.

In addition to the foregoing detailed description, a method forminiaturizing a diaper by folding and vacuum sealing and the resultingdiaper is now described with reference to FIGS. 104-129. Theminiaturizing of a diaper is accomplished by performing stepscomprising: folding and compressing a diaper within a jig; clamping andtransferring the folded compressed diaper from the jig to and insertingit into a pliable bag; and further miniaturizing the diaper within theplastic bag by vacuum sealing. The miniature size of the finishedproduct fits into a convenient size box and avoids carrying bulkydiapers within a purse or other carrying cases. The finished product iscondensed down to a firm and hard exterior surface, and is disguised inappearance to look like a candy bar instead of a baby or an adultdiaper. The process can be readily adapted to mechanical application forautomatic manufacturing assembly line runs. The following is anexemplary method for miniaturizing a diaper very compactly by foldingand vacuum sealing.

FIG. 104 is a view of a bulky diaper in the hands of a person (forreference, see Picture #1 of FIG. 114). In step 1 a bulky diaper 12 isinserted into a U-shaped elongated opened ended u-shaped forming jig 14.The diaper is laid in the jig such that the outside of the diaper 16faces downwardly with the inside of the diaper 18 facing upward.

In step 2, the ragged elastic banded edges 20 of the diaper 12 are thenfolded, i.e., tucked inwardly (for reference, see Picture #2 of FIG.115) so as to obtain a smooth clean line exterior. FIG. 105 is a sketchof a diaper within a jig made for holding and folding said diaper, witha person folding the rough edges inwardly.

In step 3, (for reference, see Picture #3 of FIG. 116), a first end 22of the diaper is folded inwardly covering a middle portion 24 of thediaper and the other end 26 of the diaper is then folded in over thefirst end 22 and middle portion 24, thereby forming a rectangular shape28 (for reference, see Picture #4 of FIG. 117). FIG. 106 is a view of adiaper with one end being folded inward. FIG. 107 is a view of a diaperwith the other end being folded inward over the first fold.

In step 5, a spring tensioned hand clamp 30 is opened with one hand 32so as to have the upper flat rectangular jaw 34 and lower jaw 36 placedover and under the completely folded diaper 28, respectively (forreference, see Pictures #5 & #6 of FIGS. 118-119). FIG. 108 shows a handclamp gripping a folded diaper.

One hand holds the hand clamp and another hand 38 compresses the diaper28 (for reference, see Picture #5 of FIG. 118). Having the folded diaper28 compressed, folded diaper 28 is inserted into an open end 40 of anelastic pliable resilient bag 42 (for reference, see Picture #8 & #9 ofFIGS. 121-122), using the hand clamp 30 and jig 14 to facilitate theinsertion. FIG. 109 shows a hand clamp held by a person compressing afolded diaper being inserted into a plastic bag, and FIG. 110 is aperspective view of a folding jig facilitating the hand clamp forinserting a diaper into a plastic bag. FIG. 111 a folded and compresseddiaper within a small plastic bag. The folded diaper 28 compressed byhand clamp 30 is directly inserted into the open ended bag 42 by hand 32(for reference, see Picture #10 & #11 of FIGS. 123-124).

In step 6, folded diaper 28, now fully inserted into the bag 42 (forreference, see Picture #12 of FIG. 125), is then placed into a vacuumsealing machine 44 on deck 46 (for reference, see Picture #13, #14 & #15of FIGS. 126-128). FIG. 112 a folded and compressed diaper within asmall plastic bag being positioned within a vacuum sealing machine. Thelid 48 of the vacuum sealing machine (for reference, see Picture #15 ofFIG. 128) is fastened down and the vacuum sealing machine 44 vacuumseals and cuts the bag 42 as a finished product 50 (for reference, seePicture #1 of FIG. 129). The finished product 50 is very firm and dense,looks like a taffy candy bar and is as small as one.

In step 7, one or more of the finished products 50 (sometimes referredto as “Vac-U-Diaper” Product) are inserted into a box 52 for convenientcarrying within a purse 54. Each Vac-U-Diaper Product measures 1 inch by2 inches by 1½ inches. FIG. 113 shows a vacuum sealed diaper within aplastic bag held by a person.

Based on the foregoing description, it will be readily understood bythose persons skilled in the art that the present invention issusceptible of broad utility and application. Many embodiments andadaptations of the present invention other than those specificallydescribed herein, as well as many variations, modifications, andequivalent arrangements, will be apparent from or reasonably suggestedby the present invention and the foregoing descriptions thereof, withoutdeparting from the substance or scope of the present invention.Accordingly, while the present invention has been described herein indetail in relation to one or more preferred embodiments, it is to beunderstood that this disclosure is only illustrative and exemplary ofthe present invention and is made merely for the purpose of providing afull and enabling disclosure of the invention. The foregoing disclosureis not intended to be construed to limit the present invention orotherwise exclude any such other embodiments, adaptations, variations,modifications or equivalent arrangements, the present invention beinglimited only by the claims appended hereto and the equivalents thereof.

1. A method of miniaturizing a single unused disposable diaper byfolding and vacuum-sealing, the diaper when worn having both an exteriorsurface including a front exterior surface and a rear exterior surface,and side elastic banded edges extending about leg openings, the methodcomprising the steps of: (a) transitioning a diaper from an initialconfiguration having an initial volume to an intermediate configurationhaving an intermediate volume, the intermediate volume being less thanthe initial volume by, (i) folding the diaper such that the width of thediaper is reduced and the side elastic banded edges of the diaper arefolded inward by, (A) folding the diaper about a first lengthwisefoldline located between the side elastic banded edges of the diaper,and (B) folding the diaper about a second lengthwise foldline locatedbetween the side elastic banded edges of the diaper, and (ii) foldingthe diaper along at least one widthwise foldline such that the length ofthe diaper is reduced generally by at least 50%, a height of the diaperbeing increased thereby, (iii) whereby a central portion of the exteriorsurface of the diaper is visible and the remainder of the exteriorsurface of the diaper is hidden from view within the folds of thediaper, and (iv) after said folding of said steps (a)(i) and (a)(ii),reducing the height of the folded diaper by compressing the diaperbetween opposed surfaces of a press; and (b) after performance of saidtransitioning of the diaper to the intermediate configuration, furthertransitioning the diaper to a final configuration having a final volumethat is less than the intermediate volume by vacuum-sealing the diaperwithin an encasement, the encasement having an interior volume thatclosely corresponds to the intermediate volume of the diaper, saidvacuum-sealing including sealing the diaper within the encasement undera vacuum that is sufficient to result in further compression of thediaper to a very firm and dense state in which the central portion ofthe exterior surface of the diaper is hard.
 2. The method of claim 1,wherein the vacuum under which the diaper is sealed within theencasement is between about 5 mbar and 1 mbar.
 3. The method of claim 1,wherein the width of the diaper is reduced generally by at least 50% insaid step (a)(i).
 4. The method of claim 1, wherein the length of thediaper is reduced generally by at least 33% in said step (a)(ii).
 5. Themethod of claim 1, wherein the length of the diaper is reduced generallyby at least 25% in said step (a)(ii).
 6. The method of claim 1, whereinthe diaper vacuum-sealed within the encasement includes a generallyrectangular configuration having three dimensions comprising a width,length, and height, and wherein the sum of two of said three dimensionsis less than 10 cm with no single dimension of said three dimensionsexceeding 10 cm.
 7. The method of claim 1, wherein the diapervacuum-sealed within the encasement includes a generally rectangularconfiguration having three dimensions comprising a width, length, andheight, and wherein none of the three dimensions exceeds about fourinches.
 8. The method of claim 1, wherein the diaper vacuum-sealedwithin the encasement includes a generally rectangular configurationhaving three dimensions comprising a final width, final length, andfinal height, and wherein the final height is approximately equal to aninitial height of the diaper in the initial configuration.
 9. The methodof claim 1, wherein the diaper vacuum-sealed within the encasementincludes a generally rectangular configuration having three dimensionscomprising a final width, final length, and final height, and whereinthe final length is between two and four inches and wherein the finalheight exceeds neither the final length nor the final width.
 10. Themethod of claim 1, wherein the encasement comprises at least a portionthereof that is transparent such that the diaper is viewable through theencasement.
 11. The method of claim 1, wherein the vacuum-sealed diaperincludes printed indicia thereon, and further comprising the step ofarranging the vacuum-sealed diaper within the encasement such that theprinted indicia is visible through a transparent portion of theencasement.
 12. The method of claim 1, wherein the diaper is the onlydiaper disposed within the encasement.
 13. The method of claim 1,wherein the encasement in which the diaper is vacuum-sealed comprises aflexible, air impermeable material.